Shadow-Imaging-Based Triangulation Approach for Tool Deflection Measurement.

As incrementally formed sheets show large geometric deviations resulting from the deflection of the forming tool, an in-process measurement of the tool tip position is required. In order to cover a measuring volume of 2.0 m × 1.0 m × 0.2 m and to achieve measuring uncertainties of less than 50 µm, a multi-sensor system based on triangulation is realized. Each shadow imaging sensor in the multi-sensor system evaluates the direction vector to an LED attached to the tool, and the three-dimensional position of the LED is then determined from the combination of two sensors. Experimental results show that the angle of view from the sensor to the LED limits both the measurement range and the measurement uncertainty. The measurement uncertainty is dominated by systematic deviations, but these can be compensated, so that the measurement uncertainty required for measuring the tool tip position in the ISF is achieved.

Gear Shape Measurement Potential of Laser Triangulation and Confocal-Chromatic Distance Sensors.

The demand for extensive gear shape measurements with single-digit µm uncertainty is growing. Tactile standard gear tests are precise but limited in speed. Recently, faster optical gear shape measurement systems have been examined. Optical gear shape measurements are challenging due to potential deviation sources such as the tilt angles between the surface normal and the sensor axis, the varying surface curvature, and the surface properties. Currently, the full potential of optical gear shape measurement systems is not known. Therefore, laser triangulation and confocal-chromatic gear shape measurements using a lateral scanning position measurement approach are studied. As a result of tooth flank standard measurements, random effects due to surface properties are identified to primarily dominate the achievable gear shape measurement uncertainty. The standard measurement uncertainty with the studied triangulation sensor amounts to >10 µm, which does not meet the requirements. The standard measurement uncertainty with the confocal-chromatic sensor is <6.5 µm. Furthermore, measurements on a spur gear show that multiple reflections do not influence the measurement uncertainty when measuring with the lateral scanning position measurement approach. Although commercial optical sensors are not designed for optical gear shape measurements, standard uncertainties of <10 µm are achievable for example with the applied confocal-chromatic sensor, which indicates the further potential for optical gear shape measurements.

Gear Shape Parameter Measurement Using a Model-Based Scanning Multi-Distance Measurement Approach.

To reduce wind turbine failures by defective drive trains, deviations in the geometry of large gears (diameter ≳ 1 m) must be extensively determined with single-digit micrometer uncertainties. Fixed measuring volumes limit standard measuring methods like coordinate and gear measuring instruments for large gear measurements. Therefore, a model-based scanning multi-distance measurement approach for gear shape parameters is presented. The measurement approach has a scalable design and consists of a confocal-chromatic sensor, rotary table as a scanning unit and model-based signal processing. A preliminary study on a midsize spur gear demonstrates the general feasibility of the model-based scanning multi-distance measurement approach. As a result, the mean base circle radius as the fundamental gear shape parameter is determined with an uncertainty of <5 µm. The calibration and adjustment of the sensor arrangement were performed with a known calibration gear. Scalability is not experimentally validated in this article. However, simulations verify the scalability of the measurement approach in a first step. For gears with 1 m in diameter and varying tooth flank geometries, the estimated achievable uncertainty of the mean base circle radius is still <5 µm. Therefore, the model-based scanning multi-distance measurement approach is a promising alternative for gear inspection.

Confocal fluorescence microscopy for geometry parameter measurements of submerged micro-structures.

Due to the challenging environment of micro-manufacturing techniques where the workpiece is submerged in a fluid, a contactless in situ capable measurement is required for quality control. However, the in situ conditions and the small specimen dimensions hinder the use of conventional metrology. Confocal fluorescence microscopy is shown to enable step height measurements of a specimen submerged in a 2.6 mm thick fluid layer with an uncertainty of 8.8 µm by fitting a model of the fluorescence intensity to the measured signal. To ascertain the potential of the proposed measurement approach, the minimal achievable uncertainty of 0.07 µm for a shot-noise-limited signal is derived.

Acoustic tonometry: feasibility study of a new principle of intraocular pressure measurement.

PURPOSE: An accurate measurement of intraocular pressure (IOP) is still essential for detecting, following-up, and treating glaucoma. The objective of the interdisciplinary project GlauPhon was to prove a new noncontact tonometry principle that analyzes the acoustic oscillation of the eye. METHOD: Three enucleated porcine eyes were infused via the optic nerve with a saline solution. The IOP was adjusted by varying the height of the infusion bottle. A speaker closed one end of a cylindrical pressure chamber and an eye was fixed to the other side. A PC sound card induced the speaker to oscillate by generating a rectangular signal (20 Hz). A pressure sensor recorded the oscillating pressure within the chamber. For each IOP a calculation was performed that characterizes the attenuation profile. RESULTS: Each series of measurements revealed an evident dependency between the amplitude difference and the IOP. The highest signal belonged to low IOP levels and it decreased with increasing IOP. The correlation of the mean acoustical signal with the given IOP showed a highly significant correlation coefficient (r=-0.98). As a result, the measured oscillation parameters are strongly dependent on the exerted IOPs. CONCLUSIONS: The experiments verified the presumed relation between the acoustic oscillation of the eye and the IOP. Nevertheless, further developments are necessary for converting the oscillation parameters into reliable IOP values, to construct a tonometry device for clinical trials.